Lightweight portable panel for physical therapy or exercise

ABSTRACT

A support panel that may provide a platform to perform, for example, for at least one of physical therapy, yoga, or Pilates exercises, is provided. The support panel includes a rigid board having a first side and a second side, which may be formed from composite materials. The support panel is configured to be placed onto a compressible surface. A padding layer is attached to the first side of the rigid board. A cover is wrapped around the padding layer and at least a portion of the second side of the rigid board. The cover may be removable. A method of using the support panel for exercises is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/181,698, filed Apr. 29, 2021, which is hereby incorporated by reference in its entirety.

INTRODUCTION

This disclosure generally pertains to lightweight rigid panels that may be placed on top of a bed or mattress, or another compressible surface, to create a stable and rigid surface for exercise, physical therapy, stretching, or sleep.

SUMMARY

A support panel that may provide a platform to perform, for example, for at least one of physical therapy, yoga, or Pilates exercises, is provided. The support panel includes a rigid board having a first side and a second side. The rigid board may be formed from composite materials.

A padding layer is attached to the first side of the rigid board. A cover is wrapped around the padding layer and at least a portion of the second side of the rigid board. In some configurations, the cover is removable.

The padding layer may be attached to the rigid board with an adhesive and, in some configurations, the padding layer may be formed from closed cell polyethylene foam. The composite material of the rigid board may include two skin layers and a honeycomb layer sandwiched between the two skin layers.

A method for using the lightweight support panel may include removing the support panel from a storage location and placing the support panel on a compressible surface. The storage location may be adjacent or nearby the compressible surface. One or more exercises may be performed on the support panel on top of the compressible surface, and then the support panel may be returned to the storage location.

The above features and advantages, and other features and advantages, of the present disclosure are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the disclosure, which is defined solely by the appended claims, when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 schematically illustrates an isometric view of an example support panel.

FIG. 2 schematically illustrates a front view of the example support panel.

FIG. 3 schematically illustrates a side view of the example support panel.

FIG. 4 schematically illustrates an enlarged side view of a portion of the example support panel.

DETAILED DESCRIPTION

Referring to the drawings, like reference numbers correspond to like or similar components wherever possible throughout the several figures. All figures may be referred to in any section of the specification, without regard to numerical order, and all figures may not show all features.

FIGS. 1-4 schematically illustrate views of a lightweight, rigid, support panel, which may simply be referred to as a support panel 10. FIG. 1 shows an isometric view of the example support panel 10 and FIG. 2 illustrates a front view of the example support panel 10. FIG. 3. schematically shows a side view of the example support panel 10 and FIG. 4 shows an enlarged portion of the example support panel 10 from FIG. 3.

The support panel 10 includes a rigid board 12 having a first side 14 and a second side 16. A padding layer 20 is attached to the first side 14 of the rigid board 12. In many configurations, the rigid board 12 will be formed from composite materials, as further described herein.

The support panel 10 is configured such that it can be placed on top of a bed, directly onto the mattress or sheets and blankets covering the mattress, to create a stable and rigid surface for exercise, stretching, or sleep. Alternatively, the support panel 10 may be used by placing it onto any compressible surface, including, without limitation, couches, futons, padded or carpeted floors, or other compressible or flexible surfaces where substantially rigid support may be needed for exercise or sleep. This disclosure involves a lightweight, rigid and padded support panel 10, which individuals can put on top of a mattress to provide a stable and rigid surface on which to lay, sit, or kneel. In particular, the support panel 10 provides a surface to properly execute physical therapy, yoga, and Pilates exercises. The support panel 10 is portable, such that it can be easily moved and easily stored.

The support panel 10 may also be used to provide a rigid surface for sleep. As described herein, the support panel 10 is lightweight such that it is easy to put on and take off the bed or mattress, especially for those who are elderly or physically compromised, and in need of, for example, physical therapy exercises. In many situations, the support panel 10 will be in a storage location adjacent, or nearby, the mattress or compressible surface upon which it is used. As used herein, the term “exercises,” includes any of the disclosed types of exercise, in addition to physical or occupational therapy, stretching, or any other types of movement that may be performed on the support panel 10, as would be recognized by those having ordinary skill in the art.

While the present disclosure may be illustrated with respect to particular industries or applications, those skilled in the art will recognize the broader applicability of the products, methods, and techniques, described herein. For example, similar structures, methods, or combinations thereof, may be used in other industries.

Those having ordinary skill in the art will also recognize that terms such as “above,” “below,” “upward,” “downward,” et cetera, are used descriptively of the figures, and do not represent limitations on the scope of the appended claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the claims in any way.

When used herein, the term “substantially” refers to relationships that are ideally perfect or complete, but where manufacturing realities prevent absolute perfection. Therefore, substantially denotes typical variance from perfection in the relevant art. For example, if height A is substantially equal to height B, it may be preferred that the two heights are 100.0% equivalent, but manufacturing realities likely result in the distances varying from such perfection. Skilled artisans would recognize the amount of acceptable variance. For example, and without limitation, coverages, areas, or distances may generally be within 10% of perfection for substantial equivalence. Similarly, relative alignments, such as parallel or perpendicular, may generally be within 5%.

Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting. Any use of the term, “or,” whether in the description or claims, is inclusive of any specific element referenced and, also, includes any combination of the elements referenced, unless otherwise explicitly stated.

Many people require physical therapy exercises to fully recover from surgery or injury, or to maintain mobility and independence. Some of these exercises require a person to lay, sit, or kneel on a solid surface to be done correctly. Ideally, this surface is the floor. However, getting down to the floor and back up may be unsafe and difficult, if not impossible, for many people, and therefore prevents the individual from doing certain exercises and impedes or prevents recovery or physical maintenance.

The person needing physical therapy exercises could buy a physical therapy table, but they are heavy and take up floor space that may not be available. Furthermore, many individuals may not be physically able to move these tables or fold them up for storage. Some individuals would like to do the physical therapy exercises in bed, but the mattress surface is too soft, preventing proper exercise form, which reduces the effectiveness of the exercise. Also, some injuries require the patient to sleep on a more rigid surface. The support panel 10 provides a solution for all these difficulties, and more.

A cover 22 may be wrapped around the support panel 10, such that it covers at least the padding layer 20. The cover 22 may also cover the first side 14 and at least a portion of the second side 16 of the rigid board 12, or may substantially cover the entire support panel 10. The cover 22 may be tightly wrapped around the remainder of the support panel 10, such that it is difficult to view in the figures, but one possible configuration for the cover 22 is shown schematically in FIG. 4. The cover 22 may create curved or fileted edges between the padding layer 20 and the rigid board 12.

In many configurations the cover 22 will be removable. Therefore, as the cover 22 is the portion of the support panel 10 that comes into contact with the person using the support panel 10, the cover 22 may be washable, replaceable, or both. Note that some configurations of the support panel 10 may not include the cover 22.

The exterior edges of the rigid board 12 may be rounded or substantially flat. An edging element, not separately numbered, may be used to surround the rigid board 12 and/or portions of the padding layer 20. The edging may be formed from any suitable material, including, without limitation, plastic edging or thick tape. The edging element may be particularly useful when the rigid board 12 is cut such that it has a rough edge. However, the rigid board 12 may also be formed with smooth edges.

As best schematically viewed in FIGS. 3 and 4, the padding layer 20 may be attached to the rigid board 12 with, for example and without limitation, an adhesive 24 or other attachment methods, such that the support panel 10 does not include fasteners or straps between the padding layer 20 and the rigid board 12. The adhesive 24 may be applied between the padding layer 20 and the rigid board 12 and is illustrated highly schematically in FIGS. 3 and 4. In one configuration, and without limitation, the padding layer 20 is permanently attached to the rigid board 12 with hot melt glue. Alternatively, hook-and-loop or other physical fasteners may be used to attach the padding layer 20 to the rigid board 12. In one configuration, the padding layer 20 may be formed from foam deposited directly onto the rigid board 12, such that it is not separately attached.

The composite material of the rigid board 12 may be formed from, for example and without limitation, two facing or skin layers with a honeycomb layer therebetween. The skin layers may be operatively attached to the honeycomb layer with one or more adhesives, and may be formed from, for example and without limitation, fiberglass or Kevlar fabric or different types of plastic or wood materials. The layers of the composite material forming the rigid board 12 may be attached or adhered together via either prepreg, or added, epoxy or epoxy resins, or similar materials, as would be recognized by skilled artisans.

The honeycomb layer may be, for example and without limitation, polypropylene, coated paper, or other suitable materials, and may be other geometric shapes, as recognized by skilled artisans. In some configurations, the rigid board 12 may be between 0.50 and 1.0 inches thick, with one preferred thickness being 0.75 inches.

The honeycomb and skin layers operate to form an I-beam structure that reduces overall weight while increasing the stiffness of the rigid board 12 and the support panel 10. In some alternative configurations, as recognizable by skilled artisans, the honeycomb may be replaced with other lightweight structures that provide a high rate of stiffness and thickness with relatively low mass.

The padding layer 20 may be formed from, for example and without limitation, closed cell polyethylene foam. This foam has low water absorbency and the correct amount of cushion, as would be recognized by skilled artisans, good durability, and reasonable cost. In some configurations, the padding layer 20 may be between 0.25 and 0.50 inches thick, with one preferred thickness being 0.375 inches.

The cover 22 may be formed from, for example and without limitation, two different portions, with the top portion, substantially covering the padding layer 20, formed from medical barrier fabric and the bottom portion, substantially covering portions of the rigid board 12, made of spandex or other suitable stretching material. The medical barrier fabric is water and bacteria resistant, and static dissipative, such that it can be wiped clean after use, which reduces the need for regular removal of the cover 22 for washing. Skilled artisans will recognize other materials suitable for the cover 22.

In practice, the support panel 10 may be used by being placed on a bed or mattress (including mattress coverings) or other compressible surface, and provides a rigid surface for a variety of exercise types. Being lightweight makes the support panel 10 easy to put on and take off the mattress, especially for users who are elderly or physically compromised. In some instances, the support panel 10 may be sold as a kit in combination with the mattress or compressible surface.

Importantly, the size and stiffness of the rigid board 12 allows the support panel 10 to distribute the body weight of the user over a large surface area. This allows the weight of a body to be supported with minimal deflection of the support panel 10 on the mattress or compressible surface, thus enabling the person to maintain proper exercise form while laying, kneeling, sitting, planking, etc. on the support panel 10 to properly execute physical therapy, yoga, or Pilates exercises.

The padding layer 20 provides a comfortable surface upon which to exercise and the cover 22 protects the padding layer 20 from damage and provides an aesthetic appearance benefit. When the support panel 10 is placed on top of a mattress or other compressible surface, it turns the bed into an elevated and rigid exercise surface or sleeping surface, eliminating the need to get down to, and back up from, the floor for those who may have difficulty doing so.

The support panel 10 is different from current exercise boards or panels that are often used on grass and sand because the support panel 10 is one piece, lightweight, stiff, has the integral padding layer 20, and the cover 22. Alterative solid wood panels are too heavy and folding panels can generate a pinch point when loaded. Note that the support panel 10 may be laid on top of the mattress without any straps, fasteners, or other attachment devices needed.

Other alternatives involve two-piece plastic and wood panels that snap together. However, these snap-together panels will not stay together as the mattress deforms under the load of the person on top and will likely fold or separate. Contrarily, the support panel 10 is rigid enough to spread the weight of the person across the mattress, such that it provides the necessary platform for physical therapy, stretching, or other movement-based exercises or activities.

The support panel 10, which may be referred to as a PHYSIOBOARD, can be easily moved and stored, but still provides a safe, effective surface for exercising and/or sleeping when placed on a mattress. The support panel 10 provides a continuous flat, rigid, padded, and covered surface when placed on a mattress and provides a safe elevated surface to properly perform physical therapy, yoga, Pilates exercises, or combinations thereof. The support panel 10 is also lightweight, making it easy for people who are elderly, injured, or disabled to put it on and take it off the bed and, importantly, to store it for subsequent use. The support panel 10 can also be used to provide a rigid surface for sleep.

The detailed description and the drawings or figures are supportive and descriptive of the disclosure. While some of the best modes and other embodiments for carrying out the disclosure have been described in detail, various alternative designs, configurations, and embodiments exist for practicing the appended claims, as will be recognized by those having ordinary skill in the art. 

1. A support panel, comprising: a rigid board having a first side and a second side, wherein the rigid board is formed from composite materials and the second side is configured to be placed onto a compressible surface; a padding layer attached to the first side of the rigid board; and a cover wrapped around the padding layer and at least a portion of the second side of the rigid board.
 2. The support panel of claim 1, wherein the cover is removable.
 3. The support panel of claim 1, wherein the padding layer is attached to the rigid board with an adhesive.
 4. The support panel of claim 1, wherein the padding layer is formed from closed cell polyethylene foam.
 5. The support panel of claim 1, wherein the composite materials of the rigid board include two skin layers and a honeycomb layer sandwiched between the two skin layers.
 6. The support panel of claim 5, wherein the padding layer is formed from closed cell polyethylene foam.
 7. The support panel of claim 6, wherein the support panel provides a platform to perform at least one of physical therapy, yoga, or Pilates exercises.
 8. The support panel of claim 2, wherein the composite materials of the rigid board include two skin layers and a honeycomb layer sandwiched between the two skin layers.
 9. The support panel of claim 8, wherein the padding layer is formed from closed cell polyethylene foam.
 10. The support panel of claim 9, wherein the padding layer is attached to the rigid board with an adhesive.
 11. A method for use of a lightweight support panel, comprising: removing the support panel from a storage location; placing the support panel on a compressible surface; performing one or more exercises on the support panel; and returning the support panel to the storage location, wherein the support panel includes: a rigid board having a first side and a second side, wherein the rigid board is formed from composite materials and the second side is configured to be placed onto the compressible surface; and a padding layer attached to the first side of the rigid board.
 12. A mattress assembly, comprising: a compressible mattress; and a support panel, having: a rigid board having a first side and a second side, wherein the second side is configured to be placed onto the compressible mattress; a padding layer attached to the first side of the rigid board, such that the padding layer is opposite the rigid board from the compressible mattress; and a cover wrapped around the padding layer and at least a portion of the second side of the rigid board, wherein the cover is removable.
 13. The mattress assembly of claim 12, wherein the rigid board is formed from composite material, and wherein the composite material of the rigid board includes two skin layers and a honeycomb layer sandwiched between the two skin layers.
 14. The mattress assembly of claim 13, wherein the padding layer is formed from closed cell polyethylene foam.
 15. The mattress assembly of claim 14, wherein the padding layer is attached to the rigid board with an adhesive. 